CN110325362B

CN110325362B - Panel suitable for assembling waterproof floor or wall coverings and method for producing the panel

Info

Publication number: CN110325362B
Application number: CN201880003817.0A
Authority: CN
Inventors: 托马斯·卢克·马丁·贝尔特; 安东尼·德莱维特
Original assignee: Chinafloors Timber China Co ltd
Current assignee: Chinafloors Timber China Co ltd
Priority date: 2017-02-28
Filing date: 2018-02-28
Publication date: 2023-06-27
Anticipated expiration: 2038-02-28
Also published as: US11053695B2; US20190383031A1; EP3589484A1; NL2018440B1; AU2018228716A1; WO2018158338A1; CN110325362A; US20210285239A1; CA3054755A1; US11619053B2; AU2018228716B2

Abstract

A panel adapted for assembling a waterproof floor or wall covering from a plurality of said panels, wherein said panel has a substantially planar top surface and a substantially planar bottom surface, said panel having a laminate structure of a plurality of layers, said layers comprising: a flexible core layer consisting essentially of a relatively low density material provided with voids in the form of air pockets, and a rigid top layer comprising a support layer consisting essentially of a relatively high density material with little air pockets, wherein the thickness of the core layer is less than the thickness of the support layer, preferably at a ratio of 0.5 or less, more preferably at a ratio between 0.5 and 0.10.

Description

Panel suitable for assembling waterproof floor or wall coverings and method for producing the panel

Technical Field

A first aspect of the invention relates to a panel adapted for assembling a waterproof floor or wall covering from a plurality of said panels, wherein said panel has a substantially flat top surface and a substantially flat bottom surface, said panel having a laminate structure of a plurality of layers comprising:

a flexible core layer, which essentially consists of a material provided with voids in the form of air pockets and thus having a relatively low density, and

a rigid top layer comprising a support layer, which support layer essentially consists of a material with little air pockets and thus a relatively high density, and wherein the density of the core layer is lower than the density of the top layer.

A second aspect of the invention relates to a method of producing a panel according to the first aspect of the invention.

Background

In the field of floor and wall coverings, initially, panels were formed based on wood or derivatives thereof. However, the main disadvantage is the hygroscopicity of this material, which reduces its suitability as a waterproof covering and affects the life and durability of such panels.

As an important alternative, in US patent 9212494, a panel based on a layer from a polyvinyl compound is proposed. The use of these compounds is advantageous because they are waterproof and relatively light weight. The proposed panel has a laminated structure of layers according to the type of interlayer: it comprises a top layer, a base layer (actually the central main layer) and a backing layer. The density of the substrate layer is relatively low and is made of a foamed synthetic material. The top layer and the backing layer are made of a polyvinyl compound, wherein at least the top layer has a higher density than the base layer. Thus, the base layer has the property of being more flexible than the top layer, which has the property of being more rigid.

In this panel, the thickness of the base layer has such dimensions that: which allows the provision of an interconnection profile of the tongue and groove type, which thereby forms an integral part of the substrate layer.

Regarding the applied density of the substrate layer, US494 teaches that in order to achieve a fine balance: on the one hand, the density should be high enough to avoid migration effects associated with any irregularities of the underlying surface from being transferred towards the upper surface of the panel. Furthermore, too soft a characteristic of the layer is to be avoided in order to prevent forces exerted on the upper surface of the panel during use from causing deformations. In addition, the transmission of sound becomes a problem with using too soft materials for use in the panel. On the other hand, the density should not become too high to avoid the creation of resonance boxes between the panel and the underlying surface by the too hard panel at any point where irregularities are present. Thus, US494 teaches that the substrate layer should have a weight of 450kg/m ³ To 900kg/m ³ Balance density between.

The panel presented in US494 does achieve adequate noise level reduction and adequate waterproof quality in terms of its utility to the end user, but other characteristics of the panel, such as rigidity and indentation performance, are compromised to the point of being practically inadequate or unsatisfactory.

In summary, when looking at the panels known in the prior art, there is still a general need in the art to develop a further improved panel which not only has interesting water and acoustic properties, but also has sufficient rigidity and/or resistance to indentation.

Disclosure of Invention

Against the above background, it is an object of the present invention to meet the above-mentioned general need by developing a technical solution which wholly or partly obviates one or more drawbacks related to panels known in the art.

The above object of the invention is fulfilled by providing a panel according to the preamble above, wherein the thickness of the core layer is smaller than the thickness of the support layer, preferably in a ratio of 0.5 or less, more preferably in a ratio between 0.5 and 0.10. Most preferably, this ratio is between 0.5 and 0.25.

The inventors have found that by reducing the thickness of the core layer compared to the support layer, a panel with sufficient waterproof and acoustic properties can be achieved which has at the same time sufficient rigidity and/or sufficient resistance to indentation.

Additional technical advantages are obtained in that the panel as a whole is not easily deformed, i.e. the curl due to temperature and humidity cycles that may be experienced during use is significantly reduced by using a relatively thin core layer in the panel.

Preferably, in the panel according to the invention, the support layer is provided directly or indirectly on the top side of the core layer.

For example, the support layer may be laminated to the core layer by applying sufficient heat and pressure, or alternatively the support layer may be glued to each other by applying an adhesive layer between the two layers.

Particularly preferably, in the panel according to the invention, the thickness of the core layer ranges from 0.5mm to 3.0mm, preferably from 0.8mm to 1.5mm.

It is further particularly preferred that in the panel according to the invention the thickness of the support layer is in the range of 2.0mm to 8.0mm, preferably 2.5mm to 4.0mm.

It should be noted that in the context of the present invention, the maximum total thickness of the panel is in the range of 4mm to 15mm, more preferably in the range of 4.5mm to 8.0 mm.

In a preferred embodiment of the panel according to the invention, the density of the core layer is 100kg/m ³ To 300kg/m ³ . It has been found that this density is properly balanced in achieving all the desired properties in accordance with the objects of the present invention.

In the panel according to the invention, the inherent voids in the core material may have the form of closed and/or open cell structures.

In particular, in the panel according to the invention, it is preferred that the material of the core layer has a foam structure. The foam structure consists essentially of a matrix in which closed cells and/or open cells are present. Foam structures are typically obtained by adding a foaming agent to the melt before it is formed and hardened into its final shape. The weight of the core layer is further reduced, which is advantageous for the panel, since the density of the foam structure is lower than for a solid structure. In addition, the foam structure has an advantage of improving sound damping characteristics compared to a solid structure.

In a further preferred embodiment of the panel according to the invention, the density of the support layer is at least 1200kg/m ³ More preferably at least 1400kg/m ³ Most preferably at least 1600kg/m ³ . Depending on the specific construction of the panel, a suitable density is typically 1800kg/m ³ To 2100kg/m ³ Within a range of (2).

Thus, the support layer contributes to a large extent to provide sufficient rigidity and indentation resistance.

Furthermore, in the panel according to the invention, the support layer has a thickness of at least 2000N/mm when measured according to the EN310 standard ² Is a part of the stiffness of the steel sheet.

The panel according to the invention preferably has a weight of at least 2000N/mm when measured according to EN310 standard ² Is included. Preferably, the overall stiffness should be 3000N/mm ² To 6000N/mm ² More preferably 4000N/mm ² To 5000N/mm ² Within (measured according to EN310 standard).

In the panel according to the invention, it is preferred that the material of the core layer comprises foam material from PE, EVA, PS, PP, PU or melamine, or cork.

In the panel according to the invention, it is preferred that the material of the support layer comprises a thermoplastic material, preferably PVC, more preferably substantially free of plasticizers and containing CaCO ₃ PVC as filler material, most preferably CaCO ₃ Is present in a content of 60 wt.%.

In a further preferred embodiment of the panel according to the invention, the material of the support layer comprises a reinforcing material, such as a glass fibre mesh or net.

Thus, the support layer is further reinforced in view of its intended use in the panel according to the invention.

Furthermore, in the panel according to the invention, the top layer preferably comprises a wear-resistant layer, which is optionally provided with a coating, and a decorative layer above the support layer.

These additional layers make the panel more suitable for its intended use as a waterproof floor or wall covering.

The coating may be a material made of urethane, acrylic or oil compound and its thickness is preferably 0.05mm to 0.10mm. The wear layer may be made of thermoplastic compounds including PVC, or of wood, paper or melamine impregnated paper. The thickness of the wear layer is preferably 0.15mm to 0.50mm. The decorative layer has a thickness of about 0.05mm to 3.0mm and is made of any suitable material, such as PVC, wood, paper, melamine impregnated paper, and cork. In addition, the decorative layer is provided with a decorative surface that can be formed by digital printing.

As is commonly applied in the top layer of the panel, the edge at the top surface may be provided with a beveled edge extending over the wear layer.

According to a preferred embodiment, in the panel the bottom side of the core layer is provided with a backing layer, either directly or indirectly.

The backing layer helps to level any irregularities of the underlying surface on which the panel is placed, and may contribute to the rigidity of the panel. In addition, the backing layer may have additional features such as grip and antimicrobial properties.

The backing layer preferably has a thickness of 0.5mm to 5.0mm, more preferably 0.8mm to 2.0mm. The material of the backing layer is a thermoplastic material, wood, paper or melamine impregnated paper.

Preferably, the material of the backing layer is PVC, more preferably contains little plasticizer and CaCO ₃ PVC as filler material, most preferably CaCO ₃ Is present in a content of 60 wt.%.

Alternatively, the material of the backing layer may be a flexible vinyl compound having a plasticizer content of at least 5wt.%.

Particularly preferably, the panel according to the invention has at least four substantially linear side edges, said side edges preferably having a rectangular design.

This design makes the panels most suitable for assembling floor or wall coverings from a plurality of panels.

In the panel according to the invention it is particularly preferred that the linear side edges comprise at least one pair of opposite side edges, which side edges are provided with interconnection coupling means for interconnecting one panel within the other panel.

Such a "floating" covering can be assembled by interconnecting the individual panels to each other at their connection sides without the use of additional coupling means such as adhesive.

Preferably, the panel according to the invention comprises two pairs of opposite side edges, which side edges are provided with interconnection coupling means.

When the panels according to the invention are provided with interconnection coupling means, these means preferably comprise a tongue and a groove, wherein the tongue is provided on one of a pair of opposite side edges and the groove is provided on the other of the same pair of opposite side edges. The design of such coupling devices is well known in the art and has proven to be well suited for panels for floating floors.

In addition, in the panel according to the invention, it is preferred that the interconnection coupling means has interlocking features that avoid free movement of the interconnection panel.

Such interlocking features may be protrusions and corresponding recesses provided on respective opposite side edges, by which adjacent panels interlock with each other.

When the panel according to the invention is provided with interconnection coupling means, these means are preferably provided as an integral part of the support layer.

In this way, the coupling means is made of a relatively hard material, which facilitates a firm connection, which is a firm embodiment of the coupling means, and which facilitates a relative convenience for the end user in coupling the devices together.

Preferably, in the panel according to the invention, the core layer and/or the support layer is an extruded sheet. Such a layer is easy to produce and the extrusion process is suitable for forming sheets with a foam structure-this is the preferred structure for the core layer.

The individual layers that make up the rigid top layer are laminated by coextrusion or calendaring under high pressure.

A particular aspect of the invention relates to a waterproof floor or wall covering consisting of a plurality of assembled panels, wherein the panels correspond to the first aspect of the invention. Such a cover benefits from the same advantages already set forth above.

Where the panels are provided with interconnection coupling means, the panels are assembled by interconnecting the interconnection coupling means from the respective adjacent panels.

In a second aspect, the invention relates to a method of producing a panel according to the first aspect of the invention, comprising the steps of:

a) Providing a flexible core layer consisting essentially of a material having a relatively low density and provided with voids in the form of air pockets;

b) Providing a rigid top layer comprising a support layer consisting essentially of a relatively high density material with little or no air pockets;

c) The adhesion of the rigid top layer to the top side of the core layer is preferably performed by applying an adhesive at the interface of the core layer and the top layer.

The method is characterized in that the thickness of the core layer is smaller than the thickness of the support layer, preferably in a ratio of 0.5 or less, more preferably in a ratio between 0.5 and 0.10.

The method according to the invention provides a new and advantageous way to provide a panel according to the first aspect of the invention.

Consistent with this, the method according to the second aspect of the invention may comprise any of the preferred features of the panel according to the first aspect of the invention.

For the panel according to the invention, the following dimensions and characteristics are preferred:

total thickness of the panel: 4.5mm to 8.0mm;

the thickness of the rigid top layer is about 3.0mm;

-the core layer has a thickness of about 1.0mm;

the thickness of the backing layer is about 1.0mm;

total width of panel: 120mm to 600mm;

-total length of panel: 300mm to 2500mm.

With respect to foam-based core layers, the following characteristics are preferred:

pore diameter: 0.01mm to 0.5mm;

void volume: 20% to 50%;

density: 100kg/m ³ To 300kg/m ³ 。

Drawings

The invention will be further explained with reference to the accompanying drawings, in which:

fig. 1 shows in perspective a preferred embodiment of a panel according to the invention;

figure 2 shows a cross section of a preferred embodiment of a panel according to the invention;

figure 3 shows a cross section of several variants of a panel according to the invention;

figure 4 shows a cross section of a panel proposed in the related art.

Detailed Description

Fig. 1 shows a panel 1 adapted to assemble a waterproof floor or wall covering by interconnecting a plurality of said panels to each other, wherein the panel has a substantially flat top surface 3 and a substantially flat bottom surface 5, and at least four substantially

linear side edges

6a, 6b, 6c, 6d, comprising at least one pair of

opposite side edges

6a, 6c, the

side edges

6a, 6c being provided with interconnecting coupling means 7, 8 for interconnecting one panel within the other panel, the panel having a sandwich structure comprising a core layer 10, a rigid top layer 12, and a backing layer 14, which substantially consist of a foam material.

Fig. 2 shows a cross section of the same embodiment as fig. 1, wherein the interconnection coupling means 7, 8 comprise a tongue 7 and a groove 8, the tongue 7 and the groove 8 having interlocking features 20a (protrusions) and 20b (grooves), respectively; free movement of the interconnected panels is avoided when the tongue of one panel is inserted into the groove of another adjacent panel.

The core layer 10 consists of an EVA-based foam structure having soft and flexible properties. The foam structure of the core layer 10 contains voids in the form of air pockets, which are schematically depicted by small circles 10 a.

The rigid top layer 12 includes a support layer 12a, a decorative layer 12b, a wear layer 12c, and a coating 12d. The support layer 12a is a rigid high density PVC material that is free of plasticizers.

The backing layer 14 is composed of an extruded PVC material that is free of plasticizers and therefore rigid.

The thickness shown generally represents the actual thickness used in the panel of the present invention. The total thickness of the panel shown is about 6mm.

Fig. 3 shows several variants of the panel with respect to the design of the side edges 6a and 6 c. The laminate structure of the layers in fig. 3 is identical to the laminate structure of the

layers

10, 12 and 14 shown in fig. 2.

Fig. 3a shows a design of the side edges 6a and 6c as shown in fig. 2, which allows interlocking two complementary side edges by a tilting-in movement;

fig. 3b shows a design of the side edges 6a and 6c, which are simply flat surfaces, wherein the side edges can be interlocked by applying an adhesive material on the contacting side edges of adjacent panels;

fig. 3c shows the design of the side edges 6a and 6c provided with classical groove 8 and tongue 7 designs, which require a horizontal transfer movement to interconnect the two panels.

Fig. 3d shows a design of the side edges 6a and 6c provided with another classical groove 8 and tongue 7 design, which allows interconnection by vertical movement or pulling down movement.

Importantly, in all of the tongue and groove designs shown, both types of interconnection coupling means form an integral part of the support layer 12 a.

For comparison reasons, in combination with the comparative examples given below, fig. 4 shows a cross section of a panel proposed in the related art.

Comparative example

The beneficial technical effects of the present invention will be further confirmed with reference to the following comparative examples:

example I.

WPC floor product (Prior Art)

So-called WPC floor panels are produced according to US9212494 and the enclosed disclosure of fig. 4.

Basically, the core layer of foam material forms the main layer of the panel, constituting more than half the total thickness of the panel (according to fig. 4). Furthermore, the tongue and groove profiles are an integral part of the core layer. The density of the core layer is about 750kg/m ³ 。

The top layer, which is arranged on the core layer of the foam material, is denser with a density of 1600kg/m ³ To 1800kg/m ³ Higher than the density value of the core layer.

The backing layer consists of EVA and PE cushion layer with density of about 200kg/m ³ 。

Example II.

Panel according to the invention

The sample plate according to the invention as shown in fig. 2 was produced with the following characteristics:

support layer:

made of PVC, which contains almost no plasticizer and CaCO ₃ As filler material, caCO therein ₃ Is present in a content of 60 wt.%.

Thickness of 2.5mm to 3.0mm.

Density of 1800kg/m ³ To 2000kg/m ³ 。

Rigid, solid nature.

Core layer:

made of EVA, PE or PS foam.

Thickness of 0.8mm to 1.5mm.

Density of 100kg/m ³ To 300kg/m ³ 。

Soft, pliable character.

A backing layer:

Thickness of 0.8mm to 2.0mm.

Density of at least 1600kg/m ³ 。

Rigid, solid nature.

Common features:

both panels I and II are provided with similar finishes, i.e. coatings, wear layers and decorative layers, on their top surfaces. The materials used are also similar and are commonly used in the art.

Comparison test:

both panels were tested as follows:

acoustic testing; according to the following criteria:

ISO 10140-1，ISO 717-2，ASTME2179-03，ASTME989-06。

indentation test; according to the following criteria:

ASTM 1914。

rigidity test; according to the following criteria:

EN 310.

the following table shows the results obtained by the above test.

As can be directly seen from the above table, the panel according to the invention not only achieves adequate acoustic properties, but also has satisfactory values in terms of resistance to indentation and rigidity.

To combine all three properties to an appropriate extent, the present invention can be said to be an improvement over the prior art, which in contrast shows insufficient values in terms of both indentation resistance and stiffness.

Claims

1. A panel for a floor or wall surface of a room adapted to be assembled from a plurality of said panels a waterproof floor or wall covering, wherein said panel has a substantially planar top surface and a substantially planar bottom surface, said panel having a laminate structure of a plurality of layers, said layers comprising:

a flexible core layer, which is composed of a material provided with voids in the form of air pockets and thus having a relatively low density, and

a rigid top layer comprising a support layer, said support layer being composed of a material having few air pockets and thus a relatively high density, and wherein the density of the core layer is lower than the density of the top layer,

it is characterized in that the thickness of the core layer is smaller than that of the supporting layer,

the density of the core layer is 100kg/m ³ To 300kg/m ³ And wherein the support layer has a density in the range of 1800kg/m ³ To 2000kg/m ³ And wherein:

the panel has a weight of at 3000N/mm when measured according to EN310 standard ² To 6000N/mm ² Overall stiffness in the range of (2);

wherein the supporting layer comprises a thermoplastic material, and the material of the supporting layer is plasticizer-free and CaCO-containing ₃ PVC as a filler material; and

the material of the core layer comprises foam material from EVA, PE, PS, PP, PU or melamine, or cork.

2. The panel of claim 1, wherein the support layer is disposed directly or indirectly on a top side of the core layer.

3. The panel of claim 1, wherein CaCO in the support layer ₃ In a content of 60 wt%.

4. The panel of claim 1, wherein the underside of the core layer is provided directly or indirectly with a backing layer.

5. The panel of claim 1, wherein the panel has at least four linear side edges.

6. The panel of claim 5, wherein the side edges have a rectangular design.

7. A panel according to claim 5, wherein the linear side edges comprise at least one pair of opposite side edges provided with interconnection coupling means for interconnecting one panel within the other panel.

8. The panel of claim 7, wherein the interconnection coupling device comprises a tongue and a groove, wherein the tongue is disposed on one of a pair of opposing side edges and the groove is disposed on the other of the same pair of opposing side edges.

9. A panel according to claim 7 or 8, wherein the interconnection coupling means is provided as an integral part of the support layer.

10. The panel of claim 1, wherein the core layer and/or the support layer is an extruded sheet.

11. A waterproof floor or wall covering consisting of a plurality of assembled panels, wherein the panels conform to any one of the preceding claims.

12. A method of producing a panel according to any one of the preceding claims 1 to 10, comprising the steps of:

a) Providing a flexible core layer, the core layer being composed of a material having a relatively low density and provided with voids in the form of air pockets;

b) Providing a rigid top layer comprising a support layer composed of a relatively high density material having little to no air pockets;

c) Adhering the top layer, which is rigid, to the top side of the core layer, by applying an adhesive at the interface of the core layer and the top layer,

the core layer is characterized in that the thickness of the core layer is smaller than that of the supporting layer.

13. The method of claim 12, wherein the core layer has a thickness less than the support layer by a ratio of 0.5 or less.

14. The method of claim 13, wherein the core layer has a thickness less than the support layer by a ratio of between 0.5 and 0.10.